Optimization of flexible fixture layout to improve form quality using parametric finite element model and mixed discrete-integer genetic algorithm

Dimensional and form accuracy of the workpiece can be improved by effective fixture layout design which shows minimum deformation of the workpiece during machining. Flexible fixtures are inevitable in industries owing to high product variety and shortened production time. Hence, an integrated approach is presented to select the optimum position of locating and clamping elements in a flexible fixture that provide good form accuracy. In this approach, a Parametric Finite Element Model (PFEM) is developed using the information about the workpiece, fixture plan and machining condition. PFEM is used to predict the elastic deformation of the workpiece for the fixture layouts generated using a discrete Genetic Algorithm (GA) with mixed integer-discrete variables. The objective is to minimize the maximum deformation of the workpiece by optimizing fixture layouts. The stability of the workpiece and fixture system is ensured by implementing non-negative reaction force constraints in GA. The proposed approach is applied for a prismatic workpiece to carry out pocket milling operation. The significance of this work is to express the flexibility and computational effectiveness of PFEM to accommodate variation in the workpiece, machining condition and fixture plan while designing flexible fixtures. Further, it highlights a significant reduction in search space due to the use of discrete GA and stability constraint as it takes less objective function calculations. An experimental analysis is performed to study the effectiveness of the proposed approach. Therefore, the proposed approach provides a viable solution to the optimization problem in flexible fixtures.